Long ultrasonic cutting blade formed of laminated smaller blades

ABSTRACT

An end effector of an ultrasonic surgical instrument is provided, the ultrasonic surgical instrument having a manipulatable structure, a body portion operatively connected to the manipulatable structure and having a distal end, a transducer, and the end effector being supported on the distal end of the body portion, the end effector including a plurality of resonant member elements, each resonant member operatively connected to a transducer of the plurality of transducers for effecting vibrations along the length of the resonant member, and including an operating surface configured to effect tissue dissection, cutting, coagulation, ligation and/or hemostasis, wherein a displacement curve associated with the vibrations of a first one of the plurality of resonant members is offset relative to the displacement curve associated with the vibrations of a second one of the plurality of resonant members.

This application claims priority to U.S. Provisional Application Ser.No. 60/328,597, filed Oct. 11, 2001, which is incorporated herein byreference in its entirety.

BACKGROUND

1. Technical Field

The present disclosure relates generally to ultrasonic surgicalinstruments. More specifically, the present disclosure relates toultrasonic surgical instruments having an end effector configured toeffect tissue dissection, cutting, coagulation, ligation and/orhemostasis, which instrument can be used in open as well as laparoscopicor endoscopic surgical procedures.

2. Background of Related Art

The use of ultrasonic instruments for surgical procedures includingdissecting, cutting, ligating, effecting coagulation in, and/oreffecting hemostasis in tissue and the benefits associated therewith arewell known. For example, the use of an ultrasonic generator inconjunction with a surgical scalpel facilitates faster and easiercutting of organic tissue. Furthermore, heat generated by frictionalcontact between the scalpel blade and the body tissue, as the scalpelblade is vibrated at a high frequency, accelerates blood vessel clottingin the area of the cut, i.e., accelerates coagulation. The speed of heatgeneration is controlled by two factors, namely the frequency of theoscillations generated by the system, (determined by the manufacturer),and the amplitude or distance of movement of the oscillations as theblade is moved (determined by the user).

Advantages associated with ultrasonic surgical instruments includeminimal lateral thermal damage, speed, absence of creation of anelectrical circuit through the patient, and absence of unwantedbyproducts such as smoke. Ultrasonic surgical instruments are suitablefor traditional open surgical procedures and are particularly suitablefor minimally invasive surgery such as laparoscopic and endoscopicsurgery.

An ultrasonic surgical instrument typically includes a manipulatablestructure, such as a hand piece, having an ultrasonic transducerconnected to an end-effector, such as a cutting/coagulating blade, via avibration coupler that conducts ultrasonic frequency longitudinalvibrations from the ultrasonic transducer to the end-effector.

The ultrasonic displacements, i.e., amplitude of the vibrationstransmitted from the transducer to the end-effector are sinusoidal bynature. The sinusoidal motion of the vibrations of the blade is alimiting factor that constrains the effective length of the blade. Atthe points along the sinusoidal curve where the amplitude is equal tozero, there is zero motion of the blade. To avoid areas of zero motionalong the blade, a blade shorter than ½ wavelength of the oscillationsis used. Currently the maximum blade length of a blade without zeromotion areas is approximately 0.250″.

Alternatively, a longer blade is used having areas of maximum motion, aswell as areas of no motion along the length of the vibrating blade. Theareas of no motion decrease the effective length of the blade,decreasing efficiency of the blade, and thus undesirably increasing thetime needed to complete the surgical procedure.

Furthermore, there are large variations in amplitude along the length ofthe blade due to the sinusoidal nature of the oscillations, resulting ininconsistent behavior of the blade, and a lack of uniform operativeresults along the length of the blade. Uniformity is desirable for aneven rate of cutting and coagulation, allowing the surgeon to proceedwith the cutting procedure at an even rate and providing the surgeonwith the ability to reliably predict results of operation of thesurgical device.

Accordingly, the need exists for a decrease in operative time byincreasing efficiency of the end-effector by increasing the effectivelength of the end-effector by reducing zero points along the sinusoidalamplitude curve. Furthermore, there is a need for increased consistencyof behavior of the end-effector for obtaining uniform operative resultsalong the length of the end-effector. Finally, the need exists for anultrasonic surgical instrument configured using Micro ElectricalMechanical Systems (MEMS) technology in which the instrument is reducedin size and weight while increasing the effective length and behaviorconsistency of the end effector.

SUMMARY

An end effector of an ultrasonic surgical instrument is provided, theultrasonic surgical instrument having a manipulatable structure, a bodyportion operatively connected to the manipulatable structure and havinga distal end, a plurality of transducers, and the end effector beingsupported on the distal end of the body portion, the end effectorincluding a plurality of resonant members, each resonant memberoperatively connected to a transducer of the plurality of transducersfor effecting vibrations along the length of the resonant member, andincluding an operating surface configured to effect tissue dissection,cutting, coagulation, ligation and/or hemostasis, wherein a displacementcurve associated with the vibrations of a first one of the plurality ofresonant members is offset relative to the displacement curve associatedwith the vibrations of a second one of the plurality of resonantmembers.

In a preferred embodiment, the plurality of resonant members is alaminate, where the laminate preferably provides a flexible bond, withthe first resonant member staggered longitudinally relative to thesecond resonant member. Preferably, the transducer includes first andsecond transducers operatively connected to the first and secondresonant members, respectively.

In another preferred embodiment, each resonant member includes a frameand a resonant structure, wherein the transducer is operativelyconnected to the resonant structure, and the resonant structure includesthe operating surface, wherein the proximal end of the resonantstructure of the first resonant member is preferably staggered relativeto the proximal end of the second resonant member. Preferably, the firstresonant member further includes a transducer of the plurality oftransducers, and the further included transducer is positioned incontact with the resonant structure of the first resonant member.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above, andthe description of the embodiments given below, serve to explain theprinciples of the invention.

FIG. 1A is a schematic representation of one embodiment of the presentlydisclosed ultrasonic surgical system including a surgical instrument forcutting, dissecting, ligating, coagulating and/or effecting hemostasisin tissue;

FIG. 1B is a schematic representation of another embodiment of thepresently disclosed ultrasonic surgical system;

FIG. 2 is a schematic top or side representation of one preferredembodiment of a plurality of resonant members of the presently disclosedultrasonic surgical instrument;

FIG. 3 is a plot of a displacement curve of a vibrating resonant memberof the ultrasonic member of the presently disclosed ultrasonic surgicalinstrument;

FIG. 4 is a plot of a displacement curve of multiple vibrating resonantmembers of the ultrasonic member of the presently disclosed ultrasonicsurgical instrument;

FIG. 5A is a side view of one preferred alternate embodiment of theresonant member of the presently disclosed ultrasonic surgicalinstrument;

FIG. 5B is a side view of another preferred alternate embodiment of theresonant member of the presently disclosed ultrasonic surgicalinstrument;

FIG. 5C is a side view of another preferred alternate embodiment of theresonant member of the presently disclosed ultrasonic surgicalinstrument;

FIG. 5D is a cross-sectional view taken along section lines X-X in FIG.5C;

FIG. 5E is a cross-sectional view of an alternate embodiment of theultrasonic member shown in FIG. D as would be seen along section lineX-X of FIG. 5C;

FIG. 5F is a cross-sectional view of an alternate embodiment of theultrasonic member shown in FIG. D as would be seen along section lineX-X of FIG. 5C;

FIG. 5G is a cross-sectional view of an alternate embodiment of theultrasonic member shown in FIG. D as would be seen along section lineX-X of FIG. 5C;

FIG. 5H is a top view of another alternate embodiment of the presentlydisclosed ultrasonic member;

FIG. 5I is a side perspective view of another embodiment of thepresently disclosed ultrasonic member;

FIG. 5J is a side perspective view of another embodiment of thepresently disclosed ultrasonic member;

FIG. 5K is a side view of another embodiment of the presently disclosedultrasonic member; and

FIG. 6 is a top or side schematic representation of a preferredembodiment of the ultrasonic member of the presently disclosedultrasonic surgical instrument.

DETAILED DESCRIPTION

An ultrasonic surgical instrument for effecting a surgical procedure atan end effector is provided, in which the end effector includes an arrayof staggered elements, where the staggering is configured so thatdisplacement curves associated with displacement of each element areoffset with respect to one another for collectively maximizing effectiveoperation and consistency of operation of the array of elements.

Preferred embodiments of the presently disclosed ultrasonic surgicalinstrument will now be described in detail with reference to thedrawings, in which like reference numerals designate identical orcorresponding elements in each of the several views. FIGS. 1A and 1Billustrate schematic views of first and second embodiments,respectively, of exemplary ultrasonic surgical system shown generally as10. System 10 includes an ultrasonic instrument 12, a control module 14and conductive cable 16 interconnecting ultrasonic instrument 12 tocontrol module 14. Ultrasonic instrument 12 may be configured for open,endoscopic or laparoscopic surgical procedures and includes an elongatedbody 20, an end effector 22, and a manipulatable structure 18operatively connected to the body 20 and/or the end effector 22 formanipulating the body and/or the end effector 22. The manipulatablestructure 18 shown in FIG. 1A is a handle assembly 18 a having a pistolgrip configuration, although other handle configurations are envisioned,e.g., in-line handle, pencil grips, standard scissor grips, newergonomically designed grips, etc. Rotation knob 13 may be provided tofacilitate rotation of elongated body 20 in a known manner.

Manipulatable structure 18 shown in FIG. 1B is a robotic system 18 bthat manipulates the body and/or the end effector 22 in accordance withcontrol signals received via cable 16. Preferably, the robotic system 18b includes a control module and a manipulation module (not shown), wherethe control module receives the control signals and controls themanipulation module to effect the desired manipulations in accordancewith the control signals. At least one of the control module and themanipulation module may be located remotely from the rest of theultrasonic instrument 12.

In another embodiment (not shown) the body 20 is omitted from theultrasonic instrument 12 and from the manipulatable structure 18, andthe end effector 22 is mounted to the manipulatable structure 18. In adifferent embodiment (not shown) the body 20 houses the manipulatablestructure 18. In still another embodiment, at least a portion of themanipulatable structure is located in or on a module remotely locatedfrom the ultrasonic instrument 12. In yet a different embodiment (notshown) the body 20 includes an elongated flexible member extendingdistally from the remotely located module to the end effector 22.

End effector 22 includes a plurality of staggered resonant members28(x), preferably formed in an array 28, where x=(1 to n), and n is thenumber of resonant members 28(x), and preferably further includes amovable, e.g., pivotable clamp member 24. Preferably, the plurality ofresonant members 28(x) a laminate made by a known process. For example,each resonant member 28(x) can be laminated by a lamination process toan adjacent resonant member 28(x). The laminate or lamination ispreferably a flexible bonding allowing for motion of one resonant member28(x) relative to an adjacent resonant member 28(x). The laminatepreferably has multiple layers.

As illustrated, control module 14 may include a power cord 15 forengagement with an electrical outlet (not shown). Alternately, controlmodule 14 may be adapted to receive power from a battery pack or from ana/c generator. It is also envisioned that a generator or other powersource may be incorporated into control module 14.

Control module 14 includes an electronic signal generator (not shown)and preferably electronic control circuitry to drive a transducer (notshown) positioned on instrument 12 at one or more ultrasonicfrequencies. Protective circuitry is preferably provided to preventinjury to a patient, a surgeon or system hardware. Control module 14also includes display circuitry and hardware (not shown) to provideinformation to and accept information from a user. This information maybe obtained from sensors (not shown) positioned on the instrument endeffector. The sensors may be provided to monitor the temperature,density, or ultrasonic or electric impedance, of the tissue beingoperated on.

Feedback circuitry may be provided to interact with any sensors providedto provide more effective ligation, cutting, dissection, coagulation,etc. For example, the feedback circuitry may terminate operation of thesystem if a sensor indicates that tissue temperature, density, orultrasonic or electrical impedance has exceeded a predetermined maximum.The ultrasonic impedance increases as tissue hardens due to risingtemperatures. Similarly, electrical impedance is reduced when tissuewater level is decreased due to overheating. The feedback circuitry maybe selectively activated and deactivated and/or controlled or monitoredby a surgeon to provide a surgeon more flexibility in operating theinstrument. Further, control module 14 may include diagnostic circuitryto aid in testing and/or debugging instrument 12 or its hardware.

It is contemplated that operation of ultrasonic instrument 12 may beautomatically controlled through the use of a computer. In one preferredalternative embodiment of the presently disclosed system, a computer 21receives data from sensors positioned on the end effector of theultrasonic instrument. As discussed above, sensors may be provided tomonitor different characteristics of the tissue being operated uponincluding, inter alia, temperature and/or ultrasonic or electricalimpedance. Computer 21 preferably includes circuitry to process ananalogue signal received from the sensor(s) and to convert the analoguesignal to a digital signal. This circuitry may include means to amplifyand filter the analogue signal. Thereafter, the digital signal can beevaluated and operation of the ultrasonic instrument can be modified toachieve the desired effect in or on the tissue and prevent damage tosurrounding tissue. Computer 21 may be incorporated into control module14 or linked to control module 14 to effect the desired or appropriatemodification of the operation of the instrument 12.

FIG. 2 shows three exemplary resonant members 28(1-3). Instrument 12 maybe configured with an array 28 having a different number of resonantmembers 28(x). The resonant members 28(1-3) can be positioned side byside so that they are transversely close to one another. The resonantmembers 28(x) are bonded or attached to one another and mounted as oneunit within elongated body 20 of the ultrasonic instrument 12, oralternatively, the resonant members 28(x) are detached from one anotherand mounted individually within the body 20 of the ultrasonic instrument12.

Proximal ends of the resonant members 28(x) are staggered relative toadjacent resonant members 28(x), and preferably the staggering distanced is uniform for each pair of adjacent resonant members 28(x), where thedistance d is determined by the number of resonant members 28(x) in thearray 28, and the wavelength of displacement curves of the resonantmembers 28(x), as described below with respect to FIG. 4. Transducers 32(one is shown) can be identically located on each respective ultrasonicmember element 28(x). Alternatively, the positioning of the transducer32 on each resonant member 28(x) may be staggered by a distance d. Thelengths of the resonant members 28(x) may be uniform or may be variable.Thus, the distal ends of the resonant members 28(x) may be even with oneanother, or may be staggered. It is contemplated that the resonantmembers 28(x), respectively, may have a variety of shapes.

The resonant members 28(x) preferably form a laminate. The laminate isformed by any known process, such as a lamination, some type of bonding,extrusion, injection, molding or combination thereof. Preferably theresonant members 28(x) are bonded to one another by a flexible materialthat allows movement of one resonant member 28(x) relative to anotherresonant member 28(x), the relative movement typically being on theorder of microns. The positioning of the bonding material for bondingadjacent resonant members 28(x) may vary with respect to designconsiderations, and thus the percentage of facing surface areas ofadjacent resonant members 28(x) having bonding material applied theretomay vary.

Resonant members 28(1-3) of instrument 12 are preferably configuredusing Micro Electrical Mechanical Systems (MEMS) technology. Resonantmembers 28(1-3) each include a body portion 30 and a resonant structure31. In the MEMs configuration shown, a transducer 32, is supported on,located between, or bonded to or within the body portion 30 of eachresonant member 28(1-3). The transducer 32 associated with eachrespective resonant member 28(x) can be an array of transducers.

Transducer 32 can be positioned on, within or adjacent resonant member28(1) to effect vibration along any axis, e.g., the x-axis, the y-axis,the z-axis or any axis in between the x, y and z axes. Resonant member28(1) includes an operating surface generally designated 42 configuredto effect dissection, cutting, coagulation, ligation and/or to effecthemostasis of tissue. Alternately, resonant member 28(1) may includemultiple operating surfaces to perform different tasks, e.g., cuttingand coagulation. System 10, including instrument 12, can be used in avariety of surgical applications including general procedures,gynecologic, urologic, thoracic, cardiac and neurological surgicalprocedures. Instrument 12 may be configured to perform both endoscopicand open surgical procedures and may be actuated via a finger switch ora foot pedal in a known manner. The actuation device may includewireless transmission circuitry to effect actuation of instrument 12.

Each transducer 32 receives an electrical signal from the electronicsignal generator (not shown) in control module 14, causing eachtransducer 32 (such as via piezoelectric or magnetostrictive elements)to be electrically excited. Each transducer 32 converts the electricalsignal into mechanical energy resulting in vibratory motion of anultrasonic frequency of transducer 32 and resonant member 28(1).Ultrasonic member 28(1) may vibrate in both high and low frequencyranges. In the low frequency range, approximately 20-100 KHz, theinstrument will cause cavitation in tissue to effect cutting of thetissue. In the high frequency range, greater than 1 MHz, the instrumentmay be used for heating and coagulation of tissue. The high and lowfrequency actuation may occur simultaneously by an electronic poweramplifier, capable of generating both frequencies. The vibratory motionis preferably primarily in a longitudinal direction. It is contemplatedthat the vibratory motion is a transverse motion, such as in Balamuthvibrations.

FIG. 3 shows a plot of a displacement curve along a vibrating resonantmember 28(1). The y-axis is the displacement/amplitude of thevibrations, and the x-axis is the length of the resonant member 28(1).The plot is sinusoidal by nature with respect to amplitude of thevibrations, and the amount of motion of the resonant member 28(1) variesalong the length of the resonant member 28(1). The amplitude of thecurve corresponds to the amount of displacement of the vibratingresonant member 28(1). Points A, B and C of the resonant member 28(1)are points of maximum motion (also known as anti-nodes), and points D, Eand F of the resonant member 28(1) are points of substantially no motionwhere the amplitude of the curve is zero (also known as nodes).

Preferably transducers 32 are piezoelectric transducers. Alternately,other transduction mechanisms, other than piezoelectric, may be usedincluding thermal stress, electrostriction, magnetostriction or opticaldrive mechanisms. Transducers 32 are connected to the electronic signalgenerator and control module 14 by an electrical connector, preferablycables 34. Cables 34 may be merged with cable 16. Cables 34 may extendproximally from transducers 32 through the body 20 of instrument 12(FIG. 1) and exit instrument 12 through an opening (not shown) in thehandle assembly 18 of the instrument for connecting to the electronicsignal generator. As shown in FIG. 3, one cable is provided for eachtransducer 32, with a first end connected to the electronic signalgenerator, and a second end connected to a respective transducer 32. Inanother embodiment one cable 34 is provided, which is connected to theelectronic signal generator at a first end and at a second end branchesinto a plurality of cable branches 34 a, with each cable branch 34 aconnected to one transducer 32 of the array of transducers.

FIG. 4 shows a plot of displacement curves 40(1-3) along vibratingresonant members 28(1-3), respectively, where the relative offset of thecurves 40(1-3) is caused by staggering of the resonant members 28(1-3)with respect to each other along the longitudinal axis. The curves40(1-3) are offset from one another such that maximum points A, B, C ofeach curve are offset from maximum points A, B, C of the other curves,respectively, and likewise for the minimum points D, E, F.

Along the length of the array 28, the combined (i.e. summed)displacement curves 40(1-3) do not have any nodes where the combinedamplitude=0, and therefore the net displacement of the vibrating array28 is always nonzero. Thus, along the entire length of the array 28there is net vibrational motion, which increases the effective length ofthe array 28 relative to a conventional ultrasonic member having onlyone vibrating element. The length of the array 28 may be extendedindefinitely such that there is net vibrational motion along the entirelength of the array 28 without any regions of zero motion.

Furthermore, along the length of the array 28, the combined displacementcurves 40(1-3) have much less variation in amplitude than a singlecombined displacement curve, and therefore the net motion along thevibrating array is relatively consistent with respect to an ultrasonicmember having only one vibrating element.

The offset between displacement curves having wavelength λ of n resonantmembers is preferably λ/n. Thus, the distance d in FIG. 2 is λ/3.Likewise, for an array having n resonant members 28(x), the distanceoffset d is preferably λ/n. In another embodiment, the distance d may beselected to be other than λ/n, and the offset of the displacement curvesof the n vibrating resonant members 28(x) may be different from λ/n.

In another embodiment, the displacement curves for different resonantmembers 28(x) have different wavelengths and/or different amplitudes. Anultrasonic member 28(x) caused to vibrate at more than one frequency mayhave more than one displacement curve, the displacement curves havingdifferent wavelengths. For example, the different transducers 32 of thearray of transducers may generate vibrations having differentfrequencies, such as by altering the input to the transducer, or havingdifferently configured transducers. Alternatively, circuitry may beprovided for altering the frequency, waveshape or amplitude,superimposing more than one frequency or a combination thereof of thevibrations generated by the transducers 32. Accordingly, the vibrationof the resonant members 28(x) may be other than sinusoidal.

It is contemplated that other means may be provided for offsetting thedisplacement curves of resonant members 28(x) relative to one another,instead of staggering the resonant members 28(x) longitudinally. Forexample, delay circuitry may be provided to at least one of the linesproviding input or output to the transducers 32 or within thetransducer. In another embodiment a control unit is provided forcontrolling operation of the transducer and/or delay circuitry foreffecting offsets of the displacement curves.

In conventional instruments the transducer is traditionally attached tothe proximal end of the hand piece and connected to the end effector ofthe instrument via an elongated vibration coupler. It is contemplatedthat the array of transducers of the present invention may be positionedsimilarly to the transducer of the conventional instruments, and that avibration coupler be provided to connect each transducer of the array toa respective resonant member 28(x) mounted at the distal end of theinstrument 12.

For MEMs configurations in which the transducers 32 are positioned on,between, or in the resonant members 28(x) adjacent the distal tip of theinstrument, the following benefits can be realized: a) the need for anelongated vibration coupler formed of titanium is obviated substantiallyreducing the cost of the instrument; b) the length of the body portionof the instrument can be changed, e.g., shortened or lengthened, withvirtually no consequential change in instrument performance, e.g., sincethe instrument vibration coupler has been replaced by an electricalconductor, the instrument need not be retuned, at considerable expense,after changes in body length; c) ultrasonic energy can be transferred toa patient more efficiently, thus lowering energy power requirements; d)the portion of the instrument that is disposable can be easily variedand may comprise only the instrument tip with a limited reuse handle,the entire instrument or any degree of disposability therebetween; e)because the handle assembly does not support the transducer, the handleassembly can be eliminated or more ergonomically configured; and f) theuse of a small transducer on, in or adjacent the distal end of theinstrument in place of a large transducer on the proximal end of theinstrument substantially reduces the weight of the instrument and makesit easy to manage especially during delicate surgical procedures.

The resonant structure 31 of each of the resonant members 28(x) ispreferably formed of a silicon or metal resonant structure or asilicon/metal composite. Alternately, materials such as titanium orother metals may be bonded or joined in some manner to the silicon toimprove fracture resistance. It is envisioned that materials other thansilicon which are suitable for ultrasonic use may be used to formresonant structure 31.

The resonant structure 31 may be formed using an etching process, e.g.,isotropic etching, deep reactive ion etching, etc. Suitable etchingprocesses are disclosed in U.S. Pat. No. 5,728,089 filed Oct. 31, 1994,which is also incorporated herein in its entirety by reference.Alternately, other known means may be used to form the ultrasonic memberincluding a variety of different mechanical processes.

The resonant structure 31 is shown as a linear blade having an operativesurface 44 (FIG. 2). FIGS. 5A-K show alternate configurations of theresonant structure 31 of resonant members 28(x), including, inter alia,J-hook (FIG. 5A), L-hook (FIG. 5B), shears (FIG. 5C) having a variety ofdifferent cross-sectional shapes (FIGS. 5D-5G), spatula (FIG. 5H),arcuate (FIGS. 5I and 5J) and rectangular (FIG. 5K). The end effectormay also be configured to have a curved blade such as the bladedisclosed in U.S. Pat. No. 6,024,750, filed on Aug. 14, 1997 and/or anangled blade, such as disclosed in U.S. Pat. No. 6,036,667, filed onOct. 4, 1996, both of which are incorporated herein in their entirety byreference.

Each of resonant members 28(x), or array 28 as an integral unit, may beattached to a distal portion of instrument 12 in any known manner. Forexample, each of resonant members 28(x) or the integral array 28 may besecured to a substrate or shaft or a mounting member (not shown)supported within a distal end of body 20 of instrument 12 such as by asnap-fit connection, a set screw or crimping or swaging. A threadedshank 40 or other attachment structure formed on or disposed on or in aproximal end of each of resonant members 28(x) or integral array 28 maybe provided for attachment of the resonant members 28(x) or array 28 tothe distal end of instrument 12.

FIG. 6 illustrates one preferred embodiment of resonant member 28(1)configured in the MEMs configuration and suitable for use in thepresently disclosed ultrasonic surgical instrument of ultrasonicsurgical system 10. Preferably resonant members 28(2-n) (not shown) havesimilar embodiments. Resonant member 28(1) is preferably a piezoelectriclaminate structure which includes a body 30 having frame 102, a resonantstructure 31, and a transducer 32. Transducer 32 preferably includes apair of PZT crystals 108 separated by silicon plate 110. Alternately, itis envisioned that crystals other than PZT crystals may be used toconvert electrical power to effect mechanical vibration. An appropriatebonding agent or process, e.g., solder bonding, diffusion bonding,adhesives, etc., is used to fasten crystals 108 to plate 110.

Resonant structure 31 preferably includes at its distal end first andsecond resonant members 104 a and 104 b. The proximal end of resonantmembers 104 a and 104 b together define a cavity for receivingtransducer 32. Alternately, resonant structure 31 may be monolithicallyformed from a single piece of material. The mating surfaces of PZTcrystals 108 and resonant members 104 a and 104 b are fastened togetherusing an appropriate flexible bonding agent or bonding process, e.g.,glass binding, adhesives, etc.

Frame 102 includes a body 112 which is preferably formed from a rigidmaterial including metals, ceramics, etc. and includes a cavity 114dimensioned and configured to receive the resonant structure 31 andtransducer 32 assembly. A bonding layer or layers 118, preferably formedof a conductive material, is positioned between the proximal portion ofresonant members 104 a and 104 b and frame 102 to bond transducer 32,which is movable, to frame 102, which is stationary. The proximal end offrame 102 includes a throughbore 120 which is dimensioned to permitpassage of an electrical conductor 122, e.g., a wire or coaxial cable,to provide power to transducer 32. The electrical conductor ispreferably a high-voltage high-frequency Teflon insulator cable,although the use of other conductors is envisioned. The distal end ofconductor 122 is connected to plate 110 by a flexible conductive wire124 which does not restrict relative movement between frame 102 andtransducer 32.

As discussed above, the shape of resonant structure 31 may be differentthan that shown in FIG. 6. More specifically, distal operating surface126 of resonant structure 31 may assume any of the configurations shownin FIGS. 5A-5K or any other configuration not shown herein which may beadvantageous for performing a particular surgical procedure. Moreover, aclamp may be provided to facilitate gripping of tissue.

In the preferred embodiment, proximal ends of resonant members 104 a and104 b of a first resonant member 28(1) of an array 28 of resonantmembers 28(x) are staggered relative to the proximal ends of a secondresonant member for effecting an offset in displacement curves of therespective resonant members.

It will be understood that various modifications may be made to theembodiments disclosed herein. For example, the configuration of theultrasonic member of the end effector need not be as shown herein butrather may be any that is suitable for the particular surgicalapplication. Further, the transducer may be mounted proximally of theultrasonic member of the end effector in the distal end of theinstrument and need not be mounted directly to the ultrasonic member.Therefore, the above description should not be construed as limiting,but merely as exemplifications of preferred embodiments. Those skilledin the art will envision other modifications within the scope and spiritof the claims appended hereto.

1. An end effector of an ultrasonic surgical instrument, the endeffector comprising: a first resonant member operatively connected to afirst transducer and a second resonant member operatively connected to asecond transducer, each transducer effecting vibrations along the lengthof the corresponding resonant member; wherein each resonant memberincludes a body portion and a resonant structure, the resonant structureextending longitudinally and distally from the corresponding bodyportion, the resonant structure including a linear blade having anoperative surface, and each transducer being directly attached to a bodyportion of the corresponding resonant member; wherein the firsttransducer is staggered longitudinally with respect to the secondtransducer resulting in a relative distance between the transducersalong a longitudinal axis of the end effector, the relative distanceremaining substantially the same during vibrations of the resonantmembers.
 2. The end effector according to claim 1, wherein thevibrations are longitudinal.
 3. The end effector according to claim 1,wherein the vibrations are transverse.
 4. The end effector according toclaim 1, wherein the first resonant member is bonded to the secondresonant member by a flexible bond.
 5. The end effector according toclaim 1, wherein the first and second resonant members are laminatedtogether by a lamination process.
 6. The end effector according to claim1, wherein the first and second resonant members are in the form of amultilayer laminate.
 7. The end effector according to claim 1, whereinthe first and second resonant members are laminated together.
 8. The endeffector according to claim 1, wherein the instrument includes amanipulatable structure.
 9. The end effector according to claim 8,wherein the manipulatable structure is operatively coupled to a moduleremotely located from the instrument.
 10. The end effector according toclaim 9, further including an elongated body extending distally from themanipulatable structure to the end effector.
 11. The end effectoraccording to claim 1, wherein each transducer is operatively connectedto its corresponding resonant structure.
 12. The end effector accordingto claim 1, wherein each resonant structure has a proximal end, and theproximal end of the resonant structure of the first resonant member isstaggered relative to the proximal end of the second resonant member.13. The end effector according to claim 1, wherein the first transducercontacts the resonant structure of the first resonant member.
 14. Theultrasonic surgical instrument according to claim 1, wherein the firstresonant member is staggered longitudinally relative to the secondresonant member.
 15. The ultrasonic surgical instrument according toclaim 8, wherein the manipulatable structure is a handle.
 16. Theultrasonic surgical instrument according to claim 1, wherein eachresonant member is situated along a longitudinal axis.
 17. Theultrasonic surgical instrument according to claim 1, wherein eachtransducer is an integral part of the end effector.
 18. The ultrasonicsurgical instrument according to claim 1, further including anelectrical conductor positioned within the ultrasonic instrument, andhaving a distal end operatively associated with each transducer and aproximal end communicating with a power source.
 19. The end effectoraccording to claim 1, wherein each resonant member includes a distalend, the distal ends of the resonant members being longitudinally spacedapart.
 20. An end effector of an ultrasonic surgical instrument, the endeffector comprising: an array of at least two resonant members, eachresonant member including a body defining a first cavity at a distal endof the body; a resonant structure defining a distal end and a proximalend, the proximal end of the resonant structure received within thefirst cavity, the distal end of the resonant structure extendinglongitudinally and distally beyond the first cavity, the resonantstructure defining a second cavity at the proximal end of the resonantstructure; and a transducer received within the second cavity, thetransducer effecting vibrations along the length of the resonant member;wherein the at least two resonant members are staggered longitudinallyrelative to each other resulting in a relative distance between eachpair of adjacent resonant members, and wherein the relative distanceremains substantially the same during vibrations of the resonantmembers.
 21. The end effector according to claim 20, wherein eachtransducer effects vibrations along the length of the correspondingresonant member such that each resonant member displays a displacementcurve from the proximal end to the distal end thereof.
 22. The endeffector according to claim 21, wherein the relative distance isdetermined by a number n of resonant members in the array and awavelength λ of the displacement curves of the resonant members.
 23. Theend effector according to claim 22, wherein the relative distance isdetermined by the formula λ/n.
 24. The end effector according to claim1, wherein each transducer is longitudinally spaced from itscorresponding resonant structure.